Cylinder Head (Cylinder Banks 1 and 2), Removing and Installing
Cylinder head (cylinder banks 1 and 2), removing and installing
This work sequence is only possible when the engine is removed from the engine compartment.
Special tools and equipment
^ 3242 Clamping bolt
^ T10068 Camshaft bar
^ T10069 Counter-holder
^ VAG 1331 Torque wrench (5...50 Nm)
^ VAG 1332 Torque wrench (40...200 Nm)
Not illustrated:
^ Drill diameter 2.0 mm
Removing
^ Remove cylinder head cover.
^ Remove fuel rail with injectors for cylinder bank 1.
^ Remove fuel rail with injectors for cylinder bank 2.
^ Remove intake manifold lower part.
Note: Seal the intake ports in the intake manifold with a clean cloth.
^ Remove coolant pipe.
^ Remove intake pipe.
^ Turn crankshaft to TDC on No. 1 cylinder.
Mark -1- must align with cylinder block joint -2-.
Cylinder bank 1
^ Remove camshaft roller chain tensioner (arrow).
^ Remove camshaft cover part.
^ Remove flywheel/drive plate sealing flange.
^ Mark roller chain before removing (e.g. with paint, arrow pointing in direction of rotation).
Note: Do not mark chain with a center punch or any similar means!
^ First remove exhaust timing camshaft adjuster and then remove intake camshaft timing adjuster.
^ Remove both camshaft timing adjusters together with camshaft roller chain from camshafts.
Note: Counter-hold only with 32 mm open jaw wrench on camshaft (arrow). Camshaft bar T10068 must not be installed when sprockets are loosened or tightened.
^ Remove guide rail for camshaft roller chain.
^ Place camshaft roller chain to one side.
^ Loosen socket head bolts in sequence given and then remove completely.
^ Carefully lift cylinder head off.
Cylinder bank 2
^ Remove camshaft cover.
^ Remove flywheel/drive plate sealing flange.
^ Release tension on camshaft roller chain tensioner and lock chain tensioner using a drill bit (diameter: 3.5 mm).
^ Mark roller chain before removing (e.g. with paint, arrow pointing in direction of rotation).
Note: Do not mark chain with a center punch or any similar means!
^ First remove exhaust timing camshaft adjuster and then remove intake camshaft timing adjuster.
^ Remove both camshaft timing adjusters together with camshaft roller chain from camshafts.
Note: Counter-hold only with 32 mm open jaw wrench on camshaft (arrow). Camshaft bar T10068 must not be installed when sprockets are loosened or tightened.
^ Remove guide rail for camshaft roller chain.
^ Place camshaft roller chain together with tensioning rail to one side.
^ Loosen socket head bolts in sequence given and then remove completely.
^ Carefully lift cylinder head off.
Installing
^ Place a clean cloth in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.
^ Also prevent dirt and emery cloth particles from getting into coolant.
^ Carefully clean cylinder head and cylinder block sealing surfaces. This ensures that no scoring or scratches are formed (when using abrasive paper the grade must not be less than 100).
^ Carefully remove metal particles, emery remains and cloths.
^ If the piston for No. 1 cylinder is not at TDC:
^ Set crankshaft to TDC No. 1 Cyl. marks -1- by turning crankshaft on vibration damper securing bolt in engine direction of rotation. When doing this, guide camshaft roller chain by hand with aid of a 2nd technician.
Mark -1- must align with cylinder block joint -2-.
Cylinder bank 1
^ Ensure that dowel sleeves are inserted into cylinder block holes 9 and 14 and that cylinder head gasket is seated.
Cylinder bank 2
^ Ensure that dowel sleeves are inserted into cylinder block holes 4 and 11 and that cylinder head gasket is seated.
Cylinder banks 1 and 2
^ Install new cylinder head gasket.
Note:
^ Only remove the new cylinder head gasket from its packing immediately before installing.
^ Handle the new gasket with extreme care. Damage to the gasket will lead to leaks.
^ Position camshafts in cylinder head to TDC No. 1 cylinder.
The camshaft bar T10068 must engage in both shaft grooves.
Note: If the camshaft bar cannot be engaged in the camshafts, turn camshafts in direction of rotation past TDC No. 1 Cyl. and then back to TDC No. 1 Cyl.
^ Install cylinder head, insert new cylinder head bolts and hand tighten.
Cylinder bank 1
^ Tighten cylinder head in tightening sequence as follows:
Note: The longer cylinder head bolts must be inserted in the middle holes of cylinder head.
^ Pretighten all bolts to 30 Nm.
^ Then tighten all bolts to 50 Nm.
^ Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.
^ Then tighten all bolts again 1/4 turn (90°) further.
Cylinder bank 2
^ Tighten cylinder head in tightening sequence as follows:
Note: The longer cylinder head bolts must be inserted in the middle holes of cylinder head.
^ Pretighten all bolts to 30 Nm.
^ Then tighten all bolts to 50 Nm.
^ Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.
^ Then tighten all bolts again 1/4 turn (90°) further.
Cylinder banks 1 and 2
The rest of the assembly is basically a reverse of the disassembling sequence.
Note: There is no requirement to retighten the cylinder head bolts after repairs.
Adjusting valve timing, Refer to Intake/Exhaust Valve, Adjustments.
Note:
^ If only the cylinder head of one cylinder bank is removed and installed, then the position of the copper links of the camshaft roller chain of the other cylinder bank need not be noted.
^ After adjusting the timing place both camshaft bars T10068 (with crankshaft positioned at TDC No. 1 cylinder) into both shaft grooves of camshafts for cylinder banks 1 and 2.